Fan array fan section in air-handling systems

Abstract

A fan array fan section in an air-handling system includes a plurality of fan units arranged in a fan array and positioned within an air-handling compartment. One preferred embodiment may include an array controller programmed to operate the plurality of fan units at peak efficiency. The plurality of fan units may be arranged in a true array configuration, a spaced pattern array configuration, a checker board array configuration, rows slightly offset array configuration, columns slightly offset array configuration, or a staggered array configuration.

What is claimed is: 
     
       1. A modular fan system configured for use in an air-handling system configured to deliver air to a ventilation system for at least a portion of a building, the modular fan system comprising:
 a plurality of modular units configured to be stacked adjacent to one another in at least one row or column to form an array for use in an air-handling system configured to deliver air to a ventilation system for at least a portion of a building, the modular units each including a chamber having a front end and a back end, the modular units are stackable adjacent to one another in the array, such that, when the modular units are stacked, the chambers open at the back ends into a common discharge plenum where the air mixes; 
 motors and fans positioned in the chambers of the modular units, the fans located to take in air from the front ends of the corresponding chambers and to discharge air from the back ends of the corresponding chambers, the motors having a corresponding first speed when driven at a frequency of 60 Hz, the fans being configured to deliver an air flow amount based on a speed of the corresponding motor; and 
 a speed controller to operate at least one of the motors at a speed that is greater than the first speed to deliver an associated air flow amount from the corresponding one of the fans. 
 
     
     
       2. The modular fan system of  claim 1 , wherein the speed controller operates the at least one of the motors at a speed that is less than or equal to the first speed to deliver an associated air flow amount from the corresponding one of the fans. 
     
     
       3. The modular fan system of  claim 1 , wherein the first speed constitutes a nameplate rated speed. 
     
     
       4. The modular fan system of  claim 1 , wherein the first speed is 1750 RPMs. 
     
     
       5. The modular fan system of  claim 1 , wherein a wheel diameter of the fans substantially equals or is between 12 inches and 44 inches. 
     
     
       6. The modular fan system of  claim 1 , wherein the wheel diameter of the fans substantially equals or is between 12 inches and 25 inches. 
     
     
       7. The modular fan system of  claim 1 , wherein spacing between said fans is between 60% and 20% of said fan wheel diameter. 
     
     
       8. The modular fan system fan array fan section of  claim 1 , wherein
 at least a portion of the chambers including sound attenuation layers that extend along at least a portion of an interior surface of the corresponding chambers, at least a portion of the sound attenuation layers being positioned between the chambers adjacent to one another. 
 
     
     
       9. The modular fan system of  claim 8 , wherein each of the chambers include top, bottom, and sides having the sound attenuation layers provided thereon. 
     
     
       10. The modular fan system of  claim 8 , wherein the sound attenuation layers include a perforated facing and at least one layer of insulation material. 
     
     
       11. The modular fan system of  claim 8 , wherein each of the chambers has a front end and a back end, wherein the fan units are oriented such that the fans are located proximate to the front ends of the chambers and the motors extend toward the back ends of the chambers. 
     
     
       12. The modular fan system of  claim 8 , wherein the sound attenuation layers are located along, and enclose, the top, bottom and sides of the fans and motors in the corresponding chambers. 
     
     
       13. The modular fan system of  claim 8 , wherein the fans constitute plenum fans. 
     
     
       14. The modular fan system of  claim 13 , wherein the speed controller includes a variable frequency drive. 
     
     
       15. The modular fan system of  claim 13 , wherein the fans are coupled to the motors in a direct drive connection. 
     
     
       16. The modular fan system of  claim 1 , wherein the fan array includes a number of fan units sufficient to at least meet a total air handling requirement for at least the portion of the building, and wherein the speed controller is sized to meet a power consumption of the fan array needed to meet the total air handling requirement. 
     
     
       17. The modular fan system of  claim 1 , wherein the fan units direct air into a common area of a discharge plenum where the air combines before exiting the discharge plenum. 
     
     
       18. The modular fan system of  claim 1 , wherein the first speed constitutes synchronous speed. 
     
     
       19. A method of providing a modular fan system configured for use in an air handling system to supply air to a building, the air handling system including an air handling compartment having a discharge plenum configured to deliver air to a ventilation system for at least a portion of the building; the method comprising:
 providing a plurality of modular units configured to be stacked adjacent to one another in at least one row or column to form an array for use in an air-handling system configured to deliver air to a ventilation system for at least a portion of a building, the modular units each including a chamber having a front end and a back end, the modular units are stackable adjacent to one another in the array, such that, when the modular units are stacked, the chambers open at the back ends into a common discharge plenum where the air mixes; 
 positioning motors and fans in the chambers of the modular units, the fans located to take in air from the front ends of the corresponding chambers and to discharge air from the back ends of the corresponding chambers, the motors having a corresponding first speed when driven at a frequency of 60 Hz, the fans being configured to deliver an air flow amount based on a speed of the corresponding motor; and 
 configuring a speed controller to operate at least one of the motors at a speed that is greater than the first speed to deliver an associated air flow amount from the corresponding one of the fans. 
 
     
     
       20. The method of  claim 19 , further comprising configuring the speed controller to operate the at least one of the motors at a speed that is less than or equal to the first speed to deliver an associated air flow amount from the corresponding one of the fans. 
     
     
       21. The method of  claim 19 , wherein the first speed constitutes a nameplate rated speed. 
     
     
       22. The method of  claim 19 , wherein the first speed is 1750 RPMs. 
     
     
       23. The method of  claim 19 , further comprising sizing a wheel diameter of the fans to be substantially equal or between 12 inches and 25 inches. 
     
     
       24. The method of  claim 19 , further comprising positioning sound attenuation layers between at least a portion of adjacent motors and fans. 
     
     
       25. The method of  claim 24 , wherein each of the chambers include a top, bottom, and sides, the method comprising providing the sound attenuation layers on at least a portion of the top, bottom and sides. 
     
     
       26. The method of  claim 24 , wherein the sound attenuation layers include a perforated facing and at least one layer of insulation material. 
     
     
       27. The method of  claim 24 , wherein the sound attenuation layers are located along, and enclose, top, bottom and sides of the fans and motors in the corresponding chambers. 
     
     
       28. The method of  claim 24 , wherein the fans are coupled to the motors in a direct drive connection. 
     
     
       29. The method of  claim 19 , wherein fan array includes a number of motors and fans sufficient to at least meet a total air handling requirement for at least the portion of the building, and wherein the speed controller is sized to meet a power consumption of the fan system needed to meet the total air handling requirement. 
     
     
       30. The method of  claim 19 , wherein the first speed constitutes synchronous speed.